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Introduction

Between 1986 and 2002 when the first Seaeye
Falcon was delivered, the company's focus had been to develop
and support a range of ROV systems from the observation class
Seaeye Tiger to the work Class Panther Plus for the offshore
oil and gas industry and to maintain its leading position
in that market by constantly seeking new ways to get more
work out of these light, powerful systems.

With the introduction of the Falcon in May
2002 the company was to bring the knowledge and experience
it had developed in this most demanding environment to other
users requiring the professional capability and reliability
associated with Seaeye ROVs but in a portable package built
to a tighter budget. The arrival of Falcon introduced a number
of interesting innovations in an ROV of this size and price
range including the replacement of the ROV electronics pod
with a distributed intelligence control system and new high
torque magnetically coupled brushless DC thrusters.

Today, Falcon customers include several NATO
navies, the Russian, Chinese, Rumanian and New Zealand Navies
as well as Special Forces in the Middle East. The ease with
which tools and sensors can be added to this modern open frame
vehicle without upsetting its performance and stability has
also found favour with scientists, environmental groups, civil
engineers and deep penetration internal tunnel surveyors.

The Seaeye Falcon DR was introduced
in 2006 following a number of successful operations conducted
by Chris Bryant of Subsea
Vision with a standard Falcon upgraded to a specification
that would form the basis of the new system. Subsea Vision's
requirement was to penetrate 1600 metres into a pipe line
running 600 metres down a mountain side in a hydroelectric
scheme. In order to transmit video and data over this length
of umbilical it was necessary to add the F2 Fibre optic pack
to his Falcon. This had previously been proven in operations
to inspect tunnels in Saudi Arabia with a Falcon fitted with
inertial navigation and in Falcons fitted with broadcast quality
cameras. The F2 fibre optics package provides a fibre optic
multiplexer in the vehicle and in the surface unit as well
as fibres in the umbilical. It was also necessary for this
operation to increase the depth rating of many of the components
used in a standard Falcon beyond 300 metres and 1000 msw was
chosen.

Falcon DR with flood light tilt linked
to camera tilt

The four vectored horizontal thrusters

The Falcon DR is rated for operations
to 1000 metres to cater for similar operations in deep tunnels
as well as for fly away operations in deeper water offshore.
(For regular operations needing a TMS, the Seaeye Tiger may
be more appropriate) This Deeper Rated Falcon DR is
easily recognised by the thicker red higher density buoyancy
material visible below the removable yellow top faring. Another
recognisable external feature is the forward facing tilting
flood lights that are linked to the camera tilt platform to
provide improved scene illumination when filming above or
below the vehicle centre line. The Falcon DR camera
tilt motor and chain drive is the same unit used in the Seaeye
Tiger.

THE VEHICLES

Vehicle Specifications

Seaeye Falcon

Seaeye Falcon DR

System Power Requirements

Single Phase100-270 VAC at 2.8 kW

Single Phase100-270 VAC at 2.8 kW

Maximum Umbilical Length

450 m

1100 m

Depth Rating

300 msw

1000 msw

Length

1000 mm

1055 mm

Height

500 mm

635 mm

Width

600 mm

600 mm

Launch Weight

60 kg

100 kg

Forward Speed

> 3 knots

> 3 knots

Thrust Forward

50 kgf

50 kgf

Thrust Lateral

28 kgf

28 kgf

Thrust Vertical

13 kgf

13 kgf

Payload

14 kg

15 kg

Chassis Layout
Saab Seaeye pioneered the use of polypropylene in the construction
of ROV frames and continues this development with the Falcon.
This material is robust, buoyant, easily drilled and machined
and is corrosion free. Falcon's modern 'open frame' design
allows the easy addition of standard bolt on accessories
including cameras, sonars, tracking systems and a single
function manipulator. Custom designed under-slung modules can also be
added for task specific tooling. 316 stainless steel fittings are used
throughout. The core frame is manufactured using modern composite materials.

Buoyancy & Payload
Buoyancy and payload is provided by securing buoyancy blocks
of the appropriate depth rating to the chassis below an easily
removable hydrodynamic faring. The faring cover also provides
protection to electronics housings and cables routed along
the top of the buoyancy to the junction box. Mounting points
on the vehicle skids are provided for lead ballast to trim
the vehicle's centre of gravity and buoyancy.

Falcon DR with faring cover in
place - note also the clear water path through the vertical
thruster

Propulsion
Brushless DC thrusters have been used on all Seaeye ROVs since
1987 when the company first introduced this technology to
the offshore oil & gas industry. These thrusters have
drive electronics with velocity feedback for precise and rapid
thrust control. A fast PID control system and a solid-state
rate gyro for enhanced azimuth stability prevent overshoot
on a change of heading as well as helping stabilise the vehicle
in forward flight making the vehicle so easy to fly.

The Falcon MCT01 thrusters are magnetically coupled
and run cool without oil. Having no moving shaft seals they
are extremely low maintenance, reliable and ideal for use
in sensitive areas such as fisheries and on reefs.

The open frame and clutter free layout between
decks in the Falcon provides the clearest water flow to 4
horizontal vectored thrusters positioned for optimum thrust
and control in all directions and superior station keeping
in strong cross currents.

Falcons are powered by 5 Seaeye Magnetically
Coupled Thruster units (MCT1) each capable of achieving 13
kgf thrust at 320W or a combined forward thrust (bollard pull)
of 50 kgf. For an ROV weighing only 50 kilos this represents
an impressive 1:1 power to weight ratio.

MCT1 Thruster Performance

Thruster Configuration

4 Vectored Horizontal Thrusters

1 Vertical Thruster

Uncluttered layout between
decks provides
optimum water flow

Distributed Intelligence Control System &
ROV Junction Box
The Falcon is the first ROV in its class to have a distributed
intelligence control system. This is a multi-drop network
that allows up to 128 devices to be connected together on
a single RS485 serial network and to be individually controlled
by a master processor.

Every controllable device on a Falcon, such as
thrusters, lights, camera tilt motor, navigation pod and manipulator
pod, contains its own microprocessor and interface and is
called a 'node'. Each of these 'nodes' is separately addressed
on the network and controlled by the master processor in the
Surface Unit. Every node is fully isolated to maximise system
reliability and each is connected into the vehicle junction
box PCB using a common through bulkhead connector. The JB
printed circuit board provides each node with its own fused
power supply and telemetry.

The Junction box also houses the video line driver
for Falcon and the F2 Fibre Optic Multiplexer for the Falcon
DR that is an optional upgrade for the standard system.

This use of distributed intelligence does away
with the traditional ROV electronics pod packed with interface
circuit boards and frees up space while significantly reducing
the weight of the vehicle.

Control System Diagnostics
Full system diagnostics are provided: A software routine automatically
checks each node when the system is powered up and alerts
are provided on the video overlay to warn the operator. The
full characteristics of each node can also be interrogated
individually from the surface unit. Local diagnostics are
also provided for each node in the Junction Box with colour
coded LEDs confirming fuse and telemetry status.

Camera System
A high resolution fixed focus colour camera is fitted to a
camera platform than can be tilted + 90 degrees. An additional
switched camera can added to Falcon and is usually mounted
on the underside of the camera tilt platform. The F2 Fibre
Optic Pack in Falcon DR - (optional in standard Falcons)
- provides 3 simultaneous video channels. Panning the camera
is achieved by turning the vehicle which it can do within
its own length.

Standard Seaeye Colour
Camera Specification

Camera Resolution

480 TVL

Min. Scene Illumination

0.2 LUX (F1.4)

Pick Up Device

1/2 Inch CCD Image Sensor

Lens

1/2" Aspherical 3.8mm lens,
wide angle fixed focus

Horizontal Field of View

91°

Tilt

±90°

Lighting
Two forward facing variable intensity 75 watt Tungsten Halogen
flood lights are fitted. An optional additional light can
be added. The lights are powered at low voltage, to improve
reliability and longevity. In the Falcon DR the forward
facing lights tilt with the camera for improved scene illumination. LED lights are offered as an option.

Standard Falcon with optional 3rd light fitted to the
camera chassis. Photo: courtesy of the
Underwater Centre Fort William

Navigation System & Auto Functions
All navigation sensors and aids are housed in a single hardened
aluminium pod. Auto depth and heading are standard fit with
auto altitude offered as an option. A pitch and roll sensor
is included and may be selected for display on the video overlay.

Falcon Surface Control unit
The Falcon and Falcon DR switch mode power supplies,
control system, fold out 15 inch LCD monitor and keyboard
are installed in a 19 inch rack mount transport case.

Seaeye
Falcon Control unit

All connections to the surface unit are on the
front panel for easy access including the hand controller
with its 5 metre flying lead.

The power output from the surface unit to the
umbilical is a galvanically isolated 500 VDC supply protected
by a L.I.M.

Optional IP68 waterproof surface unit

IP 68 monitor and controls

IP 68 Power supply
unit

IP68 is a waterproof standard
providing protection against water ingress following immersion
to a depth of 1 metre. This option is particularly popular
with military and security users operating from small boats.

Vehicle Controls on the
Hand Control Unit (HCU)

The following vehicle controls are provided on
the HCU:

Single 3 axis joystick for horizontal vehicle control
including forward, back, sideways and turn.

Rotary trim controller for vertical thrust up or down.

Push button dive and surface control

Thruster enable / disable and power setting

Camera selection

Rotary control for lights intensity

Auto pilot function for both heading & depth.

Auxiliary vehicle controls (including manipulator open/close)

Seaeye Falcon hand controller
& 5 metre lead

Dimensions

Height

180 mm

Width

280 mm

Depth

120 mm

Weight

0.5 kg

Video Overlay
A video overlay system is incorporated as standard providing
the following information to the pilot:

Compass heading

Depth

Camera tilt position

Auto pilot function status

Umbilical turns counter

Vehicle pitch and roll

CP reading

Date and time

Free Text using a QWERTY keyboard

F2 FIBRE OPTICS

The F2 Fibre Optic Pack is standard fit to the
Falcon DR and an optional upgrade for standard Falcons.
It provides the addition of a subsea and surface fibre optic
multiplexer and a suitable umbilical for transmission of video
and data over fibre optics between the surface and the vehicle.

For the standard Falcon a choice of neutrally
buoyant or thinner, slightly heavy umbilical cable is offered.
These light weight proprietary jacketed cables offer high
abrasion resistance and incorporate a Vectran strength member.

Specifications - Standard Falcon umbilicals

5733

5736

5801 (with 1 additionalScreened Twisted Pair)

Diameter

11 mm

14 mm

16 mm

Breaking Strain

530 kg

530 kg

530 kg

Weight in air

121 ± 4 kg/km

170 ± 5 kg/km

209 ± 6 kg/km

Weight in seawater

7 ± 4 kg/km

7 ± 5 kg/km

7 ± 6 kg/km

Minimum bend radius

165 mm (dynamic)110 mm (static)

197 mm (dynamic)131 mm (static)

240 mm (dynamic)160 mm (static)

For the Falcon DR and Falcons upgraded
with the F2 Fibre Optic Pack the following Fibre Optic umbilical
is used with a maximum length of 1100 metres (for longer excursions
custom designed umbilicals are available).

A choice of hand operated winches are available
including a compact wheeled Pelican case housed winch that
can accommodate a useful 295 metres of 12 mm diameter umbilical.
Electric winches are available for the longest umbilical lengths.
All have appropriate slip rings to suit the umbilical type.